SuzukiSavage.com - Exhaust leak in the middle [stock muffler]

Dave

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Re: Exhaust leak in the middle [stock muffler]
Reply #15 - Yesterday at 19:16:13

Maybe your muffler clamp area is deformed from being squeezed and the muffler needs to be expanded back to a normal shape.

Take it to a small local muffler shop that is sympathetic to guys with bikes, and have them expand the muffler until it just slides onto the header and gasket without a fight. (Or find a friend that has a pipe expanding tool).

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Riddmkidd

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Re: Exhaust leak in the middle [stock muffler]
Reply #16 - Yesterday at 22:14:32

ok I think I've got the pipe sorted. no leaks! not sure how I'm going to get it apart should I need to but so far so good. if the pipe isn't far down inside the muffler enough the mounting bolts won't line up and on my case the footpeg doesn't mount easily. I was close but not close enough. I howl this thread helps anyone else who is in a similar situation.

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Riddmkidd

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Re: Exhaust leak in the middle [stock muffler]
Reply #17 - Today at 12:00:15

Dave wrote on Yesterday at 19:16:13:

Maybe your muffler clamp area is deformed from being squeezed and the muffler needs to be expanded back to a normal shape.

Take it to a small local muffler shop that is sympathetic to guys with bikes, and have them expand the muffler until it just slides onto the header and gasket without a fight. (Or find a friend that has a pipe expanding tool).

I used a pair of needle nose pliers to spread the muffler tabs open enough so that it would fit. a proper tool like a pipe expand would have made it easier I'm sure.
going to a muffler shop was going to be my next option. thank you for the suggestion!

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